Mold-forming machine



E. l. VALYI MOLD-FORMING MACHINE Nov. 24, 1953 a sheets-sheet 1 Filed June l0,` 1952 .Guru

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III-Illllll INVENTolL v5/ey Z /AL y/ A 7mm/EY NOV. 24, 1953 E, l, vv,\| Y1 MOLD-FORMING MACHINE S Sheets-Sheet 2 Filed June lO, 1952 Nov. 24, 1953 E. vALYl MOLD-FORMING MACHINE 8 Sheets-Sheet 3 Filed June l0, 1952 w f .N mw mu 4, v RM ww mm WZ 4 M 9 W/f/ n: E it Z 7 mw... 8 8 D N A .u `7 y 8 W 5 y/ mu .h w M mv. 0 j fw M m 4 4 JM. w 2 0l V a 2 0J` MN W0/ NOV.`24, 1953 E, VA| Y| MOLD-FORMING MACHINE 8 Sheets-Sheet 4 Filed June l0, 1952 INVENTOR. /Vf/E y Z. MM Y/ Nov. 24, 1953 E. vALYl MOLD-FORMING MACHINEy 8 Sheets-Sheet 5 Filed June l0, 1952 IN V EN TOR.

5v5/ey Z. M41. y/ BY ATTORNEY EQ l. vALYl Nov. 24, 1953 MOLD-FORMING MACHINE e sheets-sheet 7 l l l Y i v l l II Filed June l0, 1952 WORM? E. vALvYl 2,659,944

MOLD-FORMING MACHINE Nov. 24, 1953 Fileduune 10, 1952v 8 sheets-sheet 8 Eme/QV 27ML Y/ TTORNEY INl/ENTO Patented Nov. 24, 1953 MOLD-FORMING MACHINE Emery I. Valy, New York, N. Y.

Application June 10, 1952, Serial No. 292,677

3 Claims.

This invention relates toan apparatus for producing foundry molds in shell form from a molding mixture comprising a refractory and a bonding agent.

The machine provides means for processing a permanent pattern in a plurality of steps for pretreating the pattern, forming the mold shell thereon, curing the shell and stripping the cured `shell from the pattern.

More specifically the machine includes a pattern carrier with ejector pins, mounted to rotate about a horizontal axis for inverting and restoring the carrier as required, a hopper carrying the molding mixture, a container for a mold release mold release liquid to the pattern prior to the next mold-forming sequence.

In the embodiment shown the oven is mounted on a carriage to shift into and out of heating relation with the pattern carrier and a mold shell thereon. The hopper is disposed at the forming station to be raised or lowered into or out of contact with the carrier and to rotate with the carrier. The container is mounted below the carrier atthe forming station to be raised or lowered as required, and the ejector pins are mounted on an ejector plate to be engaged by the hopper or by the container, according to whether the carrier is upright or inverted for stripping the mold shell from'the pattern.

k The said hopper is shown as comprising a rectangular casing which is open at the lower end thereof and is adapted to moved into and out of engagement with the pattern carrier around the periphery of the pattern. A set of louvers are mounted in the hopper between the upper and lower ends thereof and divide the hopper into two compartments. The louvers are opened and closed by suitable mechanism.

The container comprises a drain tank in which v In operation the molding mixture is placed in the upper compartment above the louvers in the sand hopper. The hopper is then lowered into engagement with the top of the pattern carrier around the periphery of the pattern. The louvers are then opened to allow the molding mixture to drop down into the lower compartment upon the preheated pattern. After the mixture has bonded into a thin layer over the pattern, the pattern carrier and hopper are inverted by rotating them in unison through 180. As the carrier and hop-l per are inverted the unbonded molding mixture falls back into the upper compartment (now the bottom compartment), leaving the thin bonded shell on the pattern. The louvers are then closed and the hopper and holder are restored to upright position, after'which the hopper is raised from the pattern carrier. The oven is then moved into position under the hopper and over and around the pattern carrier and the partially cured shell on the pattern. After the shell is cured intov a hard, rigid, strong condition, the oven is returned to its original position out of heating relation with the pattern and shell.

The drain tank is then raised to engage and elevate the ejector plate which caused the ejector pins to strip the cured shell mold upwardly from the pattern after which the shell can be removed from the machine. If it is desired to strip the shell downwardly from the pattern, vthe pattern holder is inverted and the hopper is moved downwardly to engage and depress the ejector plate.

After the shell has been stripped from the pattern, the oven is moved back into position under the hopper and over and around the pattern carrier and pattern, for preheating of the pattern. After the pattern has been heated to the desired temperature the oven is returned to its original position and the pattern carrier and pattern are inverted. The drain tank is then raised into engagement with the pattern carrier around the periphery of the pattern and the pump actuated to force the release liquid or parting solution through the spray nozzles in the drain tank to thoroughly spray the parting solution over the face of the pattern. The excess parting solution is filtered and drains back into the sump tank. The drain tank is then lowered and the carrier and pattern returned to upright position. The operation just described is then repeated for each shell mold.

When using metal patterns the refractory bonding agent mixture may comprise silica, alumina or zirconia sands or flours for the refractory, and phenol; melamine or urea formaldehyde resins or other organic or inorganic bonding agents. With this mixture the pattern may be preheated to a temperature of from 350 F. to 600 F. The pattern may be contacted with the molding mixture to a depth of several inches for from five to twenty seconds during which time the heated pattern causes the mixture contacting the pattern to bond and solidify into a layer. A partly cured shell having a uniform thickness between one-eighth and one-quarter inch is then formed over the pattern. The thickness of the shell depends on the time of contact and the temperature of the pattern. The curing oven may have a temperature between 500 F. and 900 F. Thepattern and shell are subjected to curing temperatures strong condition.

The principal object of the invention is to provide an improved single station machine for producing shell molds from a molding mixture of the character described.

Another object of the invention isito produce a machine of this type which is of .simple construction, is efcient in operation, and is rela'- tively inexpensive to manufacture.

Other and more limited objects of the invention will be apparent from the following specifica-` tion and the accompanying drawings forminga part thereof wherein:

Fig. l is a side elevation of an apparatusfor producing shell molds, which is constructed according to my invention.

Fig. 2 is a plan View, partially in section, the plane ofthe section being indicated by the line 2--2 of Fig. l;

Fig. 3 is a transverse verticalsection takenbn the line3-3 of Fig.` l;

Fig. 4 is acentral longitudinal vertical section taken on theline 4--4 of 'F.ig;.2, showing the pate tern holder in inverted position.' with the drain tank raised into engagement therewithpreparatory to spraying the face of the pattern with parting solution;

Fig. 5 is a View similar to Fig. 4 showing the sand hopper down in engagement with the vpattern holder preparatoryto opening the louvers to drop the molding mixture down upon the pattern.

Fig. 6 is a View similar to Figs. 4 and 5A showing the pattern holder and sand hopper inverted in order to return the unbonded moldingV mixture back to the upper compartment of the hopper;

Fig. 7 is a detail vertical section ltaken on the line1-1 of Fig. 2;

Fig. Sis a fragmentary detail section;

Fig. 9 is asectionalplan View, on a reduced scale, the plane -of the section being indicated by theline 9 9 on Fig. 4; and

Fig. 10 is a fragmentary longitudinalc'fral section through the upper end of the mechanism.

Referring now to the drawings by reference characters, the numeral! indicates a flat rectangular base having spaced parallel similar side frames 2 and 3 extending upwardly from each side of the forward end thereof.

The side frames 2 and 3 are provided with opposed vertical transverse slots 25, adjacent the forward ends thereof, in which a cantilever frame, generallyindicated by the numeral 26', is mounted for up and down movement. The side frames 2 and 3 are also provided. with vertical T'slots 21, formed in the outer faces thereof rearwardly' of the slots 25, in wfhich a pair of similar posts 28 are mounted for up and down movement.

The cantilever frame comprises two spaced uprights 3l, which are connected together by the transverse bars 3'2 and 33, and a pair of spaced parallel rearwardly extending horizontal arms 34 which are formed integral with the upper trans- Verse bar 32. The uprights 3! are slidably mounted in the slots 25 and each upright 3| has a rack 35 secured thereto adjacent the outer faces of the side frames 2 and 3. The racks 35 mesh with pinion gears 36 which are keyed to a transverse shaft 31 rotatably supported by the side frames 2 and 3. The shaft 31 is driven in either direction by a reversible motor 38`through a suitable speed reducer 39. The rotation of the shaft 31 in one direction or the other will move the cantilever frame up; or down in the slots 25.

Each of the posts 28 has a rack 42 secured to the outer face thereof which meshes with a gear 43 keyed vvto a shaft 44 which is rotatably supported by brackets 45 extending outwardly from the side frames 2 and 3. The forward ends of the shafts 44 have bevel gears 46 keyed thereonwhichgmeshwithlbevel gearsv 41 keyed. to a transversexshaft 48 whch'is rotatably-supported by thesidezframes 2 `andA 3 directly above the shaft 31. The shaft 48 is driven in either-direc tion by a reversible'motor iS-'through asuitab1e speed reducer 50; The rotation of the'ishaft 48' inl onefdirection or theother will mo-ve the-posts 28 up or down in unison in the T slots 21.

A pattern carrier or patternlholder, generally indicatedby the numeral 53', is-rotatablymounted between theupper ends of a pair of spaced uprights i2 which are secured to the base l by bolts il, adjacent the inner faces of the sides 2 and 3. The holder 53 comprises a rectangular frame 54 to which is securedapair offoppositely extending axially-aligned, stub shafts 55. Thev stub shafts 55 are .rotatably mounted :in .bearing apertures 55 inthe uprightl'Z, and eachlshaft 55 has a pinion gear 51 keyedY to the .outer-end thereof.V Each of the gears 51 meshes with a rack 58' which is slidably mounted in `a'guideA slot 59 in each of the'uprights 1|2.below.the gears'51; Theracks 58 vare reciprocated byair-actuated cylinder and` piston assemblies t!)l which are mounted upon brackets 61| Y secured .to the rearward edges of the uprightsV I2. Theforward movement of the racks 58 islimited -byf adjustable stops-62. 'Iihe reciprocation .of the'racks' 58 in unison. betweenftheir-.forward and rearward .positions Wllrotatethe pattern holder. 53 backand forth through 180 between upright and inverted positions.

A metalpattern 65 is'remova-bly securedby anysuitable means inthe pattern lholder'53 and rests upon an inturned flange .66. around the lower edgerof theframe 54.

An ejector .plate 61 is secured` toy thezlower ends of rods 68 which are'slidably mounted in the pattern holder frame 54 and Aextend downwardly from each corner thereof. The rods 68 are yieldingly held in their normal position when. the pattern holder is inverted, as. showninFigs. 4 and. 6, by spring-pressed balls 10 which arev mountedin bores 1l inthe pattern holder frame 54 and engage tapered notches 12in therods (itY (Fig. 8). A clamping vpl-ate 14 carrying a plurality of stripping pins 15- is removably secured to the ejector plate 61. The stripping pins. 15 extend upwardly through bores in the pattern 65 and terminate flush with the face of the pattern. l

The upper ends of the posts 28 are enlarged, as indicated at 80, and extend inwardly over the upper ends of the'uprights I2. The :opposed inner faces of the vheads of the `posts 28 are disposed in the planes of the opposed inner sur-i faces of the uprights I2. The inner faces of the heads 88 have arcuate Islots 8| formed therein which register with arcuate slots 82 in the inner surfaces of the uprights I2 when the posts 28 are in their lowermost position, as shown in Figs. 1, 3 and 7. The slots 8| and 82 when in register form a complete circle, the center of which is in the axis of the stub shaft 55.

A hopper 83 is mounted between the upper ends of the posts 28 for up and .down movement therewith. The hopper 83 comprises a rectangular frame 84 the lower end of which is open and the upper end of which is closed by a plate 85 having a door 86 therein. The front and back Walls of the frame 84 have arcuate segments 81 secured thereto which extend into the arcuate slots 8| in the heads 88 of the posts 28. The radii of curvature of the segments 81 are the same as the radii of the slots 8| and 82 so that the segments 81 may be rotated about the axis of the stub shafts 55 to move the lsegments out of the slots 8| inthe post heads 88 and into the slots 82 in the uprights I2. The hopper 83 is normally disposed over the pattern holder 53 and is adapted to be brought down into engagement with the upper edge of the pattern holder frame 54 with the inner walls of the hopper registering with the inner walls of the frame 54. When the hopper 83' is in engagement with the pattern holder 53, it is adapted to be inverted in unison with the pattern holder. During inversion the segments 81 leave the slots 8| in the post heads 88 and enter the slots 82 in the uprights I2 which maintains the hopper against the pattern holder around the pattern. During the raising .and lowering of the hopper 83 by the posts 28 the hopper is held against rotary movement by the frictional engagement Vof the arcurate segments 81 with the walls of the slots 8| in the heads 88 ofthe posts 28. When the posts 28 are holding the underside of the heads 88 in engagement with the upper ends of the uprights I2 and the bottom of the hopper in contact with the pattern holder 53, the hopper is constrained to turn with the holder and the segments 81 will ride out of the slots 8| in heads 88 and into the slots 82 in the uprights I2. The hopper 83 is divided into upper and lower compartments 88 and 89 by a set of louvers l98 which are secured to shafts 9| rotatably supported by and 'between the front and back walls of the hopper. The ends of the lshafts 9| have gears 92 secured thereto which mesh with racks 93 slidably mounted on the front `and back walls of the hopper. The racks 93 are adapted to be reciprocated by air-actuated cylinder and piston assemblies 94 which are secured to the hopper walls above the racks 93. The reciprocation of the rack 93 will move the louvers 98 back `and forth between their openand closed positions, as shown in Figs. 6 and '7.

The pattern treating mechanism by which'the pattern is cleaned and a parting solution applied thereto comprises a drain tank |88 open at the upper end thereof which is mounted upon and removably secured to the arms 34 of the ycantilever frame 216. A plurality of spray nozzles |8| are mounted in the tank |88. The parting solution is pumped under high pressure from a sump tank (not shown) to the spray nozzles I8| through a flexible hose |82. Excess solution drains back to the sump tank through a conduit |83 which is telescopically connected to the drain tank |88. A screen |84 is provided to keep any dirt or other foreign matter from draining into the sump tank with the excess parting solution.

A shell curing oven I I8 is mounted upon a vcarriage III which is reciprocally mounted upon a pair of spaced parallel channel iron tracks II2. The forward ends of the tracks |I2 Iare secured to the rear edges of the uprights I 2, adjacent the upper ends thereof, and the rear ends thereof are tied together by a cross bar I I3 and supported by posts ||4 which extend up from the base I. The carriage I I I comprises a pair of spaced parallel elongated side members II5 one of which is rigidly secured to each side of the oven I| 8. The members I I5 extend rearwardly from the oven I|8 a substantial distance and are tied together at the rear ends thereof by a cross bar II 8. Each side member II5 carries a pair of spaced rollers I I1 by which the carriage is reciprocally mounted between the channel iron tracks |I2. The oven ||8 comprises a sheet metal shell II8, open at the bottom and forward ends thereof, which is lined with suitable refractory material |I9. Suitable heating means (not shown) are mounted in or connected to the oven ||8. The carriage III and oven I|8 carried thereby are moved back and forth between operative and inoperative positions by Ia cylinder and piston assembly |28, one end of which is connected to a bracket I2| secured to and extending up from the cross bar I| 3, and the other end of which is connected to a bracket I 22 carried by the oven I I8.

In operation the molding mixture |85 is placed in the upper compartment 88 of the hopper 83. The hopper is then brought down into engagement with the upper edge of the pattern holder frame 54, as shown in Figs. 1, 3 and 5, with the hopper surrounding the pattern '65 which has been preheated and treated, as will be presently described. 'I'he louvers 98 are then opened, as shown in dotted lines in Fig. 5 and in full lines in Fig. 6. Upon the opening of the louvers 98 the molding mixture falls down into the lower compartment 89 of the hopper over the preheated pattern 65. After the mixture has been in contact with the heated pattern for a predetermined length of time the pattern holder' and hopper are rotated in unison through from the position shown in Fig. 5 to the position shown in Fig. 6. During the time the mixture is over the pattern y65 the contacting portion thereof bonds and solidiies into a partially cured shell |86 over the face of the pattern. The thickness of the shell is dependent upon the temperature of the pattern and the length of time the mixture is maintained in contact therewith. As the pattern carrier and hopper are being inverted from the position shown in Fig. 5 to the position shown in Fig. 6, the unbonded portion of the mixture falls back into compartment 88, leaving the shell |816 adhering to the face of the pattern. After the carrier and hopper have been inverted the louvers 98 are immediately closed and the carrier 'and hopper returned to the upright position shown in Fig. 5 with the mixture |85 in the compartment 88 above the louvers 98.

The hopper 83 is then raised up from the pattern holder 53 to the position shown in Fig. 4, after which the carriage II| is moved forwardly along the tracks ||2 by the cylinder and piston assembly |28 to bring the oven I I8 into operative position under the hopper 83 and over and around the pattern carrier 53 and the pattern 65 and the partially cured mold sh-ell |86 thereon as shown in Fig. 10. The oven I|8 is left in this position for a predetermined length of time during which time the curing of the mold shell |86 ispcompleted.. Afterthe Aprescribed :curing vtime under .the oven Hithe carriage H l and the .oven carried., thereby are returnedto their original position.. Thefmold-,shell- |06 is then stripped fromthe pattern.

The moldLshell maybe stripped upwardly from the :pattern while the pattern is in upright positionor theapattern maylbeinverted and the mold shell stripped downwardlytherefrom.Y If it is desired to istrip the-shell upwardly, the pattern holder and pattern are maintainedwin upright position and' thefcantileverframe-26' is raised. Theraising ofthe cantilever frame 26 rst brings the drain tankY |00-v into engagement with the ejector plate-61 and then further movement raises the' ejectorfplate andl the stripping pins 15^=which lift the moldrshell from the pattern 65; after which it is removedI from the machine. If it is.desired to strip the-mold shell downwardly 'fromthe pattern, the pattern holder is inverted'zand the hopperill is. lowered until it engagesf andv forces thefejectortplate- .61 downwardly whichzthrough thesstripping-pins 15-wi1l strip the shell downwardly; from vtheA pattern.

After a mold shell has been stripped from the f;

patternwthe oven H0 is moved `back intoopera.- tive position. overthe pattern 65 and under the hopper 8?,`v as shown. in Fig. 10, for a'sumcient time to preheattheupattern to a predetermined temperature. After preheating theY carriage IH and-oven' I l0 are1returned` vto their original position andthe pattern holder and pattern inverted... The drain tank |00 is then raised into engagement with the pattern holder around the pattern, as shown in-Fig. 4. Theuparting solu- :4

tion isthen sprayed overztheface of the pattern fromthe nozzles 1M; After sprayingthe drain tank: l U01-is *lowered* toits Aoriginal position and thepattern holder .and .pattern returned to upright posi-tion: Everything is now'in readiness forthecycle of operation to be repeated in forming thev next mold shell.

From the foregoing it will'be apparent Yto those skilled in this art .that I have provided a very simple and. eiiicient apparatus for accomplishing the objects of the invention.

Itis to be understood that Iam not limited to thefspecic construction shown and described herein as various .modicationsmay be made therein within the-spirit of ,theinvention For example the specicactuating means-'shown as pinions and piston-operated-.racks, may be replacedV by other mechanism adapted to operate in a similarmanner.

What is claimed is:

l. In an apparatus of the character described; a patternholder adapted to receive a pattern. a hopper for a molding mixture having a discharge opening at its lower end and mounted higher than said holder, closure means for said discharge opening, means operative to cause relative movement between said holder and said hopper to bring said-l hopper and said. holder into .engagement with the lower end of the hopper surrounding said pattern, meansv opening said closure'me-anssto supply molding mixture fromsaid hopper to said pattern, means operative to rotate said holder and said hopper in unison to inverted .position While maintaining said hopper in contact' with said holder for returning y excess molding mixture to said hopper, means closing said closure means, means rotating said holder and hopperto upright position, means operable to separate said hopper and said pattern holder to leave a space over said holder, an oven displaced laterally from said pattern holder and means shifting said oven into position in said space over said holder for heating the molding mixture on'said pattern.

2. An apparatus as set forth in claimv 1 in Which said hopper is mounted for vertical movement into and out of engagement with said holder.

3. In an apparatus as set forth in claim 1, a stationary frame inwhich saidholder is rotatably mounted, a carriage mounted for vertical movement in said framenab'ovesaidl holder and carrying said hopper, a second carriage mounted for lateral movement in said frame and carrying said oven.

EMERY I, VALYI.

References Citecl'in the le of thisv patent UNITED STATES PATENTS Number Name Date 2,542,243 Gedris Feb. 20, 1951 FOREIGN PATENTS Number Country Date 832,936 Germany Mar. 3, 1952 

